Woodworker's Journal 2004 Spring, страница 55

MATERIAL LIST

Making Ebony Plugs

Creating the decorative plugs for this mirror requires that you first make two sticks, each at least 12" long, to safely run through your planer. Ebony was the Greene brothers' choice for decorative plugs. Or use black-dyed maple as a more economical substitute.

I made the large 3/8" square plugs first, aiming for a perfect friction fit (no glue) in the mortises. I also made sticks from both ebony and maple, using the maple sticks to get an exact setting before I ran the ebony through my planer. Once the 3/8" plugs fit perfectly. I followed the same procedure to cut the 1/4" square plugs.

An alternative to the friction fit (also known as a press or a tap fit) would be to make the plugs a hair smaller than the mortise and secure them with a drop of poly glue.

Once you've achieved perfect fits, cut each end of your sticks square. Using 220-grit paper, sand a very slight dome on each end. Then put a buffing wheel on your bench grinder and, using some buffing rouge, polish both ends to a nice glossy finish. Slice off a 1/4" thick piece from each end at the band saw. Break the bottom corners ot each plug with sandpaper and tap the plug in place with a rubber mallet or a hammer wrapped in cloth. Repeat the whole process until you've filled all 12 mortises.

10 Spring 2004 Arts & Crafts Furniture

The 1/4" and 3/8" square ebony plugs add a decorative touch to the mahogany.